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KLF300C 1991 misfiring. Tried everything, out of ideas -ish.


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Backstory: ATV Ran fine, once stopped in the forest and had to be towed back to my workshop. Found that the stator connector was melted together. Fixed that and it ran mostly fine but intermittently lost spark. Changed CDI box which fixed that problem. Ran fine for a year, but started to misfire more and more often until it did that most of the time. It's not really losing spark, it's firing when it's not supposed to, occasionally making the engine kick in the wrong direction if the revs are low enough. I found that disconnecting the charge regulator would make the problem disappear. I measured the regulator, one diode seemed bad so I got a new one. No change. I then bought another new CDI box and changed the stator and ignition sensor as well as the ignition coil to make sure everything in the ignition circuit was new.

And now, it's still doing it. I'm leaning to a broken cable/connector somewhere but it seems illogical to me that it would spark when not supposed to if it were that. Any suggestions is very much appreciated!

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It's possible that the flywheel key has been damaged which lets the ignition timing get messed up.

You'll need a puller to remove & inspect those parts.

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Posted (edited)

Even though the problem completely disappears when I disconnect the charge regulator?, maybe I was unclear, that is still the case. Bike runs fine with it disconnected but does not charge the battery at all obviously. If it would be the flywheel key that is compromised, I believe it would still be running wonky without the charge regulator...

Edited by MaxPax
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Great point sir. Sorry, I missed that it ran perfect when regulator was disconnected. Is there 4 wires connected to the regulator? Two going to stator, one going to ground,  and one going to the battery?

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If there are 6 wires, check the brown wire going to engine stop switch for damage causing a short to ground. Oftentimes, wires have been hacked and the colors may vary.

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I realize the schematic is 1988, I believe the 91 is the same. (Not positive, going off memory) If not, you will know immediately after viewing. It sounds based on your description, that one of the wires coming out of the regulator is shorting to ground. Possibly, the regulator itself has a bad diode as well. Difficult to diagnose without being able to test. I'm hoping these ideas will in some way direct you to the problem. Many times, if voltage is less then 14.5 at the battery with engine running at about half throttle, the rectifier is bad. Not 100 percent, could also be a wire short circuit in the mix.

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I checked, the brown wire was indeed shorted to ground. I pulled it out of the connector and the few minutes I let the bike running it seemed to run just fine. Before though, after changing the cdi box and stator, it seemed to run fine for about a day until it wonked out, so I am excited but a bit reserved about this. However, it's charging 14,5 volts on idle and 14,55 volts with half throttle.

You sir might just deserve a bunch of free pizzas, if it stays fine now I will be a happy man with some extra parts laying around, like a fully working stator assembly haha.

Question now, can I leave the brown wire out? The reverse light works and the stop switch works, seems there would be a reason for that wire to be there. Can it be disconnected without causing other problems down the line? Maybe the wisest thing to do is to find out where it grounds and fix it...

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I'm at work now sir....I'll get back to you. I believe it goes to the kill switch. If engine shuts off with wire disconnected, you may be ok ( may be a redundant ground for safety).....I'll take a peak at wiring diagram this evening.

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Check ALL lights, make sure there are no issues. I'm a bit sceptical as well.

The problem could also be in the ignition switch. (The switch is on same circuit)

Sometimes, the ignition switch contacts get rusted and results in fluctuating voltage. Kawasaki's are not happy when the voltage/current is not perfect!

However, since the regulator is testing perfect, I'm assuming the ignition switch is not causing issues. Therefore,  it appears the issue is isolated to the wire shorting to ground.

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      A03GJ50AB
      2003 Trail Boss 330 Service Manual
      2004 Sportsman 6X6 Parts Manual
      A04CL50AA
      2004 Sportsman 6X6 Owners Manual
      2004 Sportsman 6X6 Service Manual
      2004 Sportsman 400,500,600 and 700 Owners manual
      2004 Sportsman 400 Parts Manual rev.1
      A04CH42AA
      A04CH42AE
      A04CH42AG
      2004 Sportsman 400 Parts Manual rev.1
      A04CH42AQ
      A04CH42AT
      A04CH42AV
      A04CH42AS
      A04CH42AR
      2004 Sportsman 500 Parts Manual rev.1
      A04CH50AA
      A04CH50AC
      A04CH50AE
      A04CH50AG
      2004 Sportsman 500 Parts Manual rev.1
      A04CH50AO
      A04CH50AQ
      A04CH50AR
      A04CH50AS
      A04CH50AT
      A04CH50AV
      A04CH50AW
      2004 Sportsman 600 Parts Manual rev.2
      A04CH59AF
      A04CH59AH
      A04CH59AJ
      A04CH59AT
      A04CH59AV
      2004 Sportsman 600 Parts Manual rev.1
      A04CH59AK
      A04CH59AL
      A04CH59AN
      A04CH59AW
      2004 Sportsman 600 and 700 Service Manual
      2004 Sportsman 700 Parts Manual rev.2
      A04CH68AC
      A04CH68AF
      A04CH68AH
      A04CH68AJ
      A04CH68AT
      A04CH68AV
      2004 Sportsman 700 Parts Manual
      A04CH68AK
      A04CH68AL
      A04CH68AN
      A04CH68AO
      2004 Sportsman 700 MV Parts Manual
      A04CH68MB
      2004 Sportsman 700 MV Service Manual
      2004 Ranger 2X4 Parts Manual
      A04RB42AA
      2004 Ranger 4X4 Parts Manual
      A04RD50AA
      2004 Ranger 6X6 Parts Manual
      A04RF50AA
      2005 Sportsman 6X6 Parts Manual
      A05CL50AA
      2005 Sportsman 6X6 Owners Manual
      2005 Sportsman 6X6 Service Manual
      2005 Sportsman 400,500.600 and 700 Owners Manual
      2005 Sportsman 400 Parts Manual
      A05MH42AB
      A05MH42AG
      A05MH42AH
      2005 Sportsman 400 and 500 Service Manual
      2005 Sportsman 500 HO/INT'L Parts Manual
      A05MH50AB
      A05MH50AC
      A05MH50AG
      A05MH50AH
      A05MH50FB
      2005 Sportsman 600 Parts Manual
      A05MH59AK
      A05MH59AN
      2005 Sportsman 700 Parts Manual
      A05MH68AK
      A05MH68AN
      2005 Sportsman 700 EFI Parts Manual
      A05MH68AC
      A05MH68AS
      A05MH68AU
      A05MH68AW
      2005 Sportsman 700 EFI and 800 EFI Service Manaul
      2005 Sportsman 800 EFI Parts Manual
      A05MH76AC
      A05MH76AU
      A05MH76AW
      2005 Sportsman MV7 Parts Manaul
      A05MH68AP
      2005 Sportsman MV7 Service Manual
      2006 Outlaw 500 Service Manual
      2007 Sportsman 6X6 Service Manual
      2007 Sportsman 450 Service Manual
      2007 Sportsman 500 EFI Service Manual
      2007 Sportsman 500 X2 EFI Service Manual
      2007 Sportsman 700 Service Manual
      2007 Sportsman 800 Service Manual
      2007 Sportsman 800 EFI Service Manual
      2007 Sportsman 700 MV Parts Manual
      A07MH68MA
      2007 Sportsman 700 MV Service Manual
      2007 Outlaw 500 Service Manual
      2007 Ranger 700 EFI 6X6 Parts Manual
      R07RF68AD
      R07RF68AF
      2007 Ranger XP 4X4 Service Manual
      2007 Ranger XP 6X6 Service Manual
      2008 Sportsman 500 Service Manual
      2008 Sportsman 500 EFI Service Manual
      2008 Sportsman X2 500 EFI Service Manual
      2008 Sportsman Touring 500 EFI Service Manual
      2008 Sportsman X2 700 Service Manual
      2008 Sportsman 800 EFI Service Manual
      2008 Sportsman 800 Touring Service Manual
      2008 Ranger 6X6 700 EFI Parts Manual
      R08RF68AD
      R08RF68AF
      2009 Sportsman 6X6 800 EFI Service Manual
      2009 Sportsman 90 Service Manual
      2009 Sportsman 300 Service Manual
      2009 Sportsman 400 HO Service Manual
      2009 Sportsman 500 HO Service Manual
      2009 Sportsman 500 EFI Service Manual
      2009 Sportsman X2 500 EFI Service Manual
      2009 Sportsman Touring 500 EFI Service Manual
      2009 Sportsman 800 EFI Service Manual
      2009 Sportsman X2 800 EFI Service Manual
      2009 Sportsman Touring 800 EFI Service Manual
      2009 Sportsman XP 550 Service Manual
      2009 Sportsman XP 550 EPS Service Manual
      2009 Sportsman XP 850 Service Manual
      2009 Sportsman XP 850 EPS Service Manual
      2009 Outlaw 90 Service Manual
      2009 Outlaw 450 MXR Service Manual
      2009 Outlaw 525 S Service Manual
      2009 Outlaw 525 IRS Service Manual
      2009 Predator 50 Service Manual
      2009 Ranger RZR Service Manual
      2009 Ranger RZR S Service Manual
      2009 Ranger INT'L Service Manual
      2009 Ranger 2x4 Service Manual
      2009 Ranger 4x4 Crew Service Manual
      2009 Ranger 6x6 Service Manual
      2009 Ranger 500 4x4 EFI Service Manual
      2009 Ranger RZR 170 Service Manual
      2009 Ranger XP 700 4x4 Service Manual
      2009 Ranger HD 700 4x4 Service Manual
      2009 Scrambler 500 Service Manual
      2009 Trail Blazer 330 Service Manual
      2009 Trail Boss 330 Service Manual
      2010 Ranger RZR Service Manual
      2010 Ranger RZR S Service Manual
      2010 Ranger INT'L Service Manual
      2011 Ranger RZR SW Service Manual
      2011 Ranger RZR Service Manual
      2011 Ranger RZR S Service Manual
      2011 Ranger RZR 4 Service Manual
      Other Stuff
      2500lb Polaris Winch Install Instructions and Parts List
      2500lb Warn Winch Install Instructions
      2500lb Warn Winch Parts Manual
      Warn Winch Motor Rotation Instructions
      Warn - The Basic Guide to Winching Techniques
      Sportsman 600 and 700 Ignition Replacement Kit Install Instructions
      Polaris Special Tools - ATV,Snowmobile,Watercraft
      Download Manuals HERE
       
      Some ATV manuals available in the downloads section at https://www.quadcrazy.com/files/
      Find them on on:
      Get 15% at emanualsonline.com with coupon code EMOAFF
      Get 20% at emanualsonline.com with coupon code BLAZE and $50 purchase
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